Method for manufacturing a semiconductor package having a conductive pad with an anchor flange

ABSTRACT

A semiconductor package includes a molding compound, a chip and a conductive pad, wherein the chip is electrically connected to the conductive pad and both are encapsulated in the molding compound. An anchor flange is formed around a top surface of the conductive pad by over plating. When the conductive pad is embedded in the molding compound, the anchor flange engages the molding compound to prevent the conductive pad from separation. Bottoms of a chip and the conductive pad are exposed from the molding compound for electrically soldering to a circuit board.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application (DIV) of U.S. patent application Ser. No. 16/920,908, filed on Jul. 6, 2020, issued as U.S. Pat. No. 11,562,947, the disclosures of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a semiconductor package and a method for manufacturing the same, particularly to a method by which the semiconductor package can be manufactured in low package height.

2. Description of the Related Art

Semiconductor devices can be manufactured in different package types. Minimizing the sizes of the semiconductor packages to implement high-density arrangement in a limited space is the main trend of the semiconductor packaging technique. For quad flat no-lead (QFN) packages or dual flat no-lead (DFN) packages, since soldering pads of those packages are formed on their bottoms instead of extending from sides of the packages, the QFN/DFN products have a lower height than packages of the past.

With reference to FIGS. 10A to 10E, a conventional QFN packaging process is illustrated. In FIG. 10A, a lead frame 200 is etched to form a die pad 201 and a plurality of intermediate leads 202. A chip 203 can be attached on the die pad 201 and electrically connected to the die pad 201. The lead frame 200 may be made of copper or other conductive materials.

With reference to FIG. 10B, the chip 203 is electrically connected to the plurality of the intermediate leads 202 through bonding wires 204.

With reference to FIG. 10C, a molding compound 18 is formed by a molding process to cover the chip 203, the die pad 201, the bonding wires 204 and the intermediate leads 202.

With reference to FIG. 10D, a bottom surface of the lead frame 200 is processed by a second etching process such that the intermediate leads 202 become the finished leads 206. Further, a partial bottom of the molding compound 205 is exposed.

With reference to FIG. 10E, an insulating layer 207 is provided to cover a portion of the finished leads 206.

The QFN package manufactured by the foregoing processes can be soldered to a circuit board (not shown) through the die pad 201 and the finished leads 206.

However, the semiconductor package still needs to be improved. Since the die pad 201 and the finished leads 206 are manufactured based on the lead frame 200, an uneven surface of the lead frame 200 may result in soldering problems. Further, the poor coverage of the insulation layer 207 on the finished leads 206 may cause problems of copper exposure.

SUMMARY OF THE INVENTION

An objective of the present disclosure is to provide a semiconductor package. The semiconductor package comprises:

-   -   a molding compound having a top surface and a bottom surface;     -   a chip encapsulated in the molding compound and having a bottom         on which a solder layer is formed, the solder layer being         exposed from the bottom surface of the molding compound; and     -   a conductive pad encapsulated in the molding compound and         electrically connected to the chip and having         -   a bottom exposed from the bottom surface of the molding             compound;         -   a perpendicular side surface; and         -   an anchor flange formed around a top surface of the             conductive pad to engage the molding compound.

Another objective of the present disclosure is to provide a manufacturing method of a semiconductor package. The method comprises:

-   -   defining a die-bonding region on a carrier and forming a         conductive pad on the carrier, wherein the conductive pad has a         perpendicular side surface and an anchor flange formed by over         plating and around a top surface of the conductive pad;     -   bonding a chip on the die-bonding region of the carrier;     -   electrically connecting the chip to the conductive pad;     -   forming a molding compound to encapsulate the chip and the         conductive pad; and     -   etching the carrier to expose bottoms of the chip and the         conductive pad from a bottom of the molding compound.

Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A to 1C are cross-sectional views showing a process of manufacturing conductive pads on a substrate;

FIG. 2 is a cross-sectional view of the conductive pad;

FIGS. 3A to 3F are cross-sectional views of packaging processes of the present disclosure, wherein a wire-bonding process is used for electrical connection;

FIG. 4A is a top view of a dual lead semiconductor package;

FIG. 4B is a bottom view of the dual lead semiconductor package of FIG. 4A;

FIG. 5 is a cross-sectional view of a three-lead semiconductor package with bonding wires;

FIGS. 6A to 6G are cross-sectional views of packaging processes of the present disclosure, wherein a redistribution process is used for electrical connection;

FIG. 7 is a cross-sectional view of a three-lead semiconductor package with a redistribution layer;

FIG. 8A to 8D are cross-sectional views showing a process of manufacturing conductive pads on a substrate in accordance with another embodiment of the present invention;

FIG. 9A is a top view of a dual lead semiconductor package manufactured based on a carrier formed by processes of FIGS. 8A to 8D;

FIG. 9B is a bottom view of the dual lead semiconductor of FIG. 9A; and

FIGS. 10A to 10E are cross-sectional views showing a conventional method of manufacturing QFP semiconductor packages.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure relates to a semiconductor package such as a quad flat no-lead (QFN) package or a dual flat no-lead (DFN) package. In the following description, a diode package is taken as an example of the semiconductor package for purpose of describing the present disclosure.

With reference to FIGS. 1A to 1C, a manufacturing process of conductive pads on a carrier are shown. In FIG. 1A, a photomask 11 made through a photolithography process is applied on a carrier 10. The carrier 10 may be a copper foil, a strip, a wafer, a panel, etc. The patterns of the photomask 11 are determined based on product types. For example, areas covered by the photomask 11 on the carrier 10 are defined as die-bonding regions while other areas uncovered by the photomask 11 are defined as conductive pad regions. An electroplating process is performed to form a composite conductive layer on the conductive pad regions. In the embodiment of FIG. 1B, the composite conductive layer is formed by sequentially plating an aurum layer (Au) 21, a nickel layer (Ni) 22, a copper layer (Cu) 23, a nickel layer (Ni) 24 and an aurum layer (Au) 25 on the carrier 10. However, the electroplating materials and sequence may be varied by demands and are not limited to the examples listed above. In the present disclosure, by controlling the electroplating time of the copper layer 23, the conductive pad regions on the carrier 10 are deliberately over-plated so that the copper layer 23 is slightly above the top surface of the photomask 11. As shown in FIG. 1B, the top surface of the copper layer 23 is above the top surface of the photomask 11. The nickel layer 24 and the aurum layer 25 are subsequently plated on the copper layer 23. After the electroplating process is completed, the photomask 11 is removed from the carrier 10. The composite conductive layer remaining on the carrier 10 constitutes the conductive pad 20.

As shown in FIG. 2 , because an over plating operation is deliberately performed on the carrier 10, the conductive pad 20 has the mushroom-shaped appearance with a perpendicular side surface and an anchor flange 26 around the top surface of the conductive pad 20.

The carrier 10 with the conductive pads 20 formed thereon may further be processed by subsequent packaging processes as shown in FIGS. 3A to 3F.

With reference to FIG. 3B showing the die-bonding process, a chip 30 is bonded on the die-bonding region of the carrier 10. The height of the chip 30 is approximately equal to the height of the conductive pad 20 so that the top of chip 30 is substantially co-planar with the top of the conductive pad 20. The top surface of the chip 30 is provided with at least one connecting pad 31 and the bottom of the chip 30 may be electroplated by metal material in advance to form a solder layer 32.

With reference to FIG. 3C, after the chip 30 is bonded on the carrier 10, the wire-bonding process is performed to connect the connecting pad 31 of the chip 30 to the respective conductive pad 20 via a wire 33.

With reference to FIG. 3D, after the wire-bonding process, the molding process is performed to encapsulate the chip 30 and the conductive pad 20 with a molding compound 40.

With reference to FIG. 3E, after the molding process, the carrier 10 is removed by etching such that the solder layer 32 of the chip 30 and the bottom of the conductive pad 20 are exposed. A sawing process is then performed to cut the molding compound 40 along the paths as indicated by the broken lines on FIG. 3E.

With reference to FIG. 3F, after the sawing process, a plurality of individual semiconductor packages 100 is manufactured. For each of the semiconductor packages 100, the anchor flange 26 of the conductive pad 20 engages the molding compound 40 to enhance interlock between the conductive pad 20 and the molding compound 40 and prevent the conductive pad 20 from separation.

FIG. 4A shows a top view of the semiconductor package 100, wherein the chip 30 and the conductive pad 20 are similar in size. FIG. 4B shows a bottom view of the semiconductor package 100. In this embodiment, the semiconductor package 100 is a dual-lead element such as a diode having an anode and a cathode. The solder layer 32 of the chip 30 and the bottom of the conductive pad 20 function as two solder leads of the dual-lead element for electrically mounting on a circuit board. In the example of FIGS. 4A and 4B, the size of the solder layer 32 is similar to the size of the bottom of the conductive pad 20.

With reference to FIG. 5 , the processes of the present disclosure discussed above may be applied to manufacture a three-lead or multi-lead semiconductor package 100. During the wire-bonding process, different connecting pads 31 a, 31 b on the chip 30 are connected to respective conductive pads 20 via multiple wires 33. The bottoms of the conductive pads 20 and the chip 30 constitute a plurality of solder leads of the multi-lead semiconductor package 100.

In another embodiment, the electrical connection between the chip 30 and the conductive pad 20 is implemented by a redistribution-layer (RDL) process shown in FIGS. 6A to 6G instead of the wire-bonding process.

With reference to FIGS. 6A and 6B, because the processes of forming the conductive pad 20 and die-bonding are the same as shown in FIGS. 3A and 3B, the detailed descriptions for FIGS. 6A and 6B are omitted to avoid redundant description.

With reference to FIG. 6C, after the die-bonding process, a dielectric layer 50 is coated on the carrier 10 and etched through the photolithography process to define a wire pattern, wherein parts of the connecting pad 31 of the chip 30 and the conductive pad 20 are exposed from the wire pattern.

With reference to FIG. 6D, an electroplating process is performed to form a redistribution layer (RDL) as connection circuits 60 for connecting the connecting pad 31 of the chip 30 to the conductive pad 20. In one embodiment, the connection circuits 60 are made of aurum.

With reference to FIGS. 6E to 6G, after the redistribution layer is formed, subsequent molding, carrier 10 etching and sawing processes similar to steps of FIGS. 3D to 3F are performed to complete the semiconductor packages 100.

As shown in FIG. 7 , the connection circuits 60 made by the redistribution layer may be used to fabricate the three-lead or multi-lead semiconductor package 100. Different connecting pads 31 a, 31 b on the chip 30 are connected to respective conductive pads 20 via the connection circuits 60. The bottoms of the conductive pads 20 and the chip 30 constitute a plurality of solder leads of the semiconductor package 100.

With reference to FIGS. 8A to 8D, for a semiconductor package having a specific appearance request, the soldering pads of the semiconductor package should be formed in a specific size and shape. In order to meet the requirement, die pads 36 with needed size and shape may be pre-manufactured on the carrier 10 for connecting the chip 30.

With reference to FIG. 8A, a first photomask 71 made through photolithography is applied on a carrier 10 to define patterns of the conductive pads 20 as well as die pads 36. The surface of the carrier 10 uncovered by the first photomask 71 is plated to form an aurum layer 21 (Au) and a nickel layer 22 (Ni) sequentially.

With reference to FIG. 8B, after removing the first photomask 71, the aurum layer (Au) 21 and the nickel layer (Ni) 22 corresponding to patterns of the chips 30 form a die pad 36.

With reference to FIG. 8C, a second photomask 72 made through photolithography is applied on the carrier 10 to cover the die pads 36. The regions exposed from the second photomask 72 are then plated to form a copper layer (Cu) 23, a nickel layer (Ni) 24 and an aurum layer (Au) 25 sequentially. The multi-layer structure composed of the aurum layer (Au) 21, the nickel layer (Ni) 22, the copper layer (Cu) 23, the nickel layer (Ni) 24 and the aurum layer (Au) 25 forms a conductive pad 20.

With reference to FIG. 8D, after the conductive pad 20 is formed, the second photomask 72 is removed from the carrier 10, wherein the conductive pads 20 as well as the die pads 36 remain on the carrier 10. The chip 30 can be bonded on the die pad 36 and electrically connected to the neighboring conductive pads 20 through wire bonding or RDL processes.

With reference to FIGS. 9A and 9B, when the carrier 10 manufactured through the steps of 8A to 8D is applied to packaging processes, since the die pad 36 for electrically connecting the chip 30 is exposed from the bottom of the molding compound 18, the die pad 36 functions as the plated solder layer 32 discussed in FIG. 4B. Therefore, the distribution, sizes or shapes of solder pads of the semiconductor package 100 are substantially determined by the die pads 36 and the conductive pads 20.

In short, the semiconductor package and manufacturing method thereof in accordance with present disclosure at least have the following features:

-   -   1. Because the semiconductor package is not manufactured based         on any lead frame used, the problems resulted from the lead         frame such as copper exposure and uneven surface of the lead         frame are avoided.     -   2. The thickness of the semiconductor package is reduced as much         as possible.     -   3. By simply controlling the electroplating process, the         conductive pad is manufactured to form an anchor flange for         engaging the molding compound. As a result, the separation of         the conductive pad and the molding compound can be avoided.

Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only. Changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. 

What is claimed is:
 1. A manufacturing method of a semiconductor package comprising steps of: forming a conductive pad on a carrier and forming a die-bonding region beside the conductive pad by electroplating on the carrier, wherein the conductive pad has a perpendicular side surface and an anchor flange formed around a top surface of the conductive pad by over plating on a predetermined photomask, wherein the top surface of the conductive pad is a curved surface above a top surface of the predetermined photomask; bonding a chip on the die-bonding region on the carrier without overlapping the conductive pad, the chip having a bottom on which a flat solder layer is comprehensively formed, said chip and said flat solder layer in combination having a height approximately equal to a height of the conductive pad in order that a top of the chip is substantially co-planar with the top surface of the conductive pad; electrically connecting the chip to the conductive pad that is manufactured in a way different from how the flat solder layer is formed; forming a molding compound to encapsulate the chip and the conductive pad; and etching the carrier to expose the flat solder layer of the chip and the conductive pad from a bottom of the molding compound; wherein the conductive pad differs from the flat solder layer in shape and is thicker than the flat solder layer.
 2. The method as claimed in claim 1, wherein the step of forming the conductive pad further comprises steps of: over plating the conductive pad region to form a composite conductive layer; removing the predetermined photomask from the carrier to keep the composite conductive layer remaining on the carrier as the conductive pad.
 3. The method as claimed in claim 1, wherein the step of forming the conductive pad further comprises steps of: providing a first photomask on the carrier to define a conductive pad region and the die-bonding region on the carrier; electroplating the conductive pad region and the die-bonding region on the carrier, wherein a die pad is formed on the die-bonding region by electroplating; removing the first photomask from the carrier; providing the predetermined photomask on the carrier, wherein the conductive pad region is exposed from the predetermined photomask; over plating the conductive pad region to form a composite conductive layer; removing the predetermined photomask from the carrier to keep the composite conductive layer as the conductive pad.
 4. The method as claimed in claim 2, wherein in the step of over plating the conductive pad region to form the composite conductive layer, a metal material that comprises aurum, nickel, copper or a combination thereof is deposited on the carrier.
 5. The method as claimed in claim 3, wherein in the step of over plating the conductive pad region to form the composite conductive layer, a metal material that comprises aurum, nickel, copper or a combination thereof is deposited on the carrier.
 6. The method as claimed in claim 4, wherein the chip is connected to the conductive pad through a redistribution layer.
 7. The method as claimed in claim 5, wherein the chip is connected to the conductive pad through a redistribution layer. 